Just as a quick update and certainly a lesson learned for me
Rather than editing it all manually like last time, I have just tried the FormDuplicator tool and it fixed it.
I decided to compare the 2 versions in Notepad which indicentally I have never done before. There seemed to be a lot of erroneous characters in the bad file like little squares. I am assuming this will be extra chr(13) or chr(10) but i havent looked to check it fully.
anyway thought I would let you all know. Its fixed and formduplicator is a good tool